U.S. patent application number 11/777365 was filed with the patent office on 2009-01-15 for chimney cap with replaceable or recyclable ceramic catalytic filter insert.
This patent application is currently assigned to John G. Arnold, JR.. Invention is credited to John G. Arnold, JR., Joseph D. Smith.
Application Number | 20090017741 11/777365 |
Document ID | / |
Family ID | 39212204 |
Filed Date | 2009-01-15 |
United States Patent
Application |
20090017741 |
Kind Code |
A1 |
Arnold, JR.; John G. ; et
al. |
January 15, 2009 |
CHIMNEY CAP WITH REPLACEABLE OR RECYCLABLE CERAMIC CATALYTIC FILTER
INSERT
Abstract
A chimney cap device for a flue opening. The device includes a
tubular housing with an open lower end and an open upper end. A
plurality of louver openings in a lower portion of the tubular
housing draw air into the tubular housing. A removable top is
attached to the open upper end of the tubular housing wherein the
top includes a plurality of exit openings. A liner is provided
within and attached to the tubular housing. A removable catalytic
converter insert is supported within the liner to treat emissions
from a gas fired appliance.
Inventors: |
Arnold, JR.; John G.;
(Tulsa, OK) ; Smith; Joseph D.; (Owasso,
OK) |
Correspondence
Address: |
HEAD, JOHNSON & KACHIGIAN
228 W 17TH PLACE
TULSA
OK
74119
US
|
Assignee: |
Arnold, JR.; John G.
Tulsa
OK
|
Family ID: |
39212204 |
Appl. No.: |
11/777365 |
Filed: |
July 13, 2007 |
Current U.S.
Class: |
454/35 ; 60/274;
60/299 |
Current CPC
Class: |
F23G 7/07 20130101; F23J
15/025 20130101; F23L 17/02 20130101 |
Class at
Publication: |
454/35 ; 60/274;
60/299 |
International
Class: |
F23L 17/02 20060101
F23L017/02; F01N 3/10 20060101 F01N003/10 |
Claims
1. A chimney cap device for a flue opening, which device comprises:
a tubular housing with an open lower end and an open upper end; a
plurality of louver openings in a lower portion of said tubular
housing to draw air into said tubular housing; a removable top
attached to said open upper end of said tubular housing wherein
said top includes a plurality of exit openings; a liner within and
attached to said tubular housing; and a removable filter insert
within said tubular housing.
2. A chimney cap device for a flue opening as set forth in claim 1
including an inner frame and mounting assembly attached near said
open lower end of the tubular housing having anchoring and leveling
means to anchor said inner frame and mounting assembly.
3. A chimney cap device for a flue opening as set forth in claim 2
wherein said inner frame and mounting assembly includes receptacles
and wherein said anchoring and leveling means includes a plurality
of clips receivable in said receptacles.
4. A chimney cap device for a flue opening as set forth in claim 1
wherein said tubular housing is fabricated from flat sheet
metal.
5. A chimney cap device for a flue opening as set forth in claim 4
wherein said louver openings are stamped into said flat sheet
metal.
6. A chimney cap device for a flue opening as set forth in claim 1
wherein said tubular housing has a cross-section in a form chosen
from the group consisting of an octagon, a hexagon, a square, a
rectangle, or a circle.
7. A chimney cap device for a flue opening as set forth in claim 1
wherein said removable top is fastened to said tubular housing by
fasteners.
8. A chimney cap device for a flue opening as set forth in claim 1
wherein said top includes a heat deflector to direct gases toward
said exit openings.
9. A chimney cap device for a flue opening as set forth in claim 1
including a plurality of supports to uphold said filter insert.
10. A chimney cap device for a flue opening as set forth in claim 9
wherein said plurality of supports extend from said liner.
11. A chimney cap device for a flue opening as set forth in claim 1
wherein said filter insert is a catalytic converter.
12. A chimney cap device for a flue opening as set forth in claim
11 wherein said catalytic converter includes a core or substrate, a
washcoat, and a catalyst.
13. A chimney cap device for a flue opening as set forth in claim
12 wherein said core or substrate is a ceramic honeycomb structure
with gas flow passages.
14. A chimney cap device for a flue opening as set forth in claim
12 wherein said washcoat and catalyst are applied to said core or
substrate.
15. A chimney cap device for a flue opening as set forth in claim 1
wherein said flue opening includes an upstanding flue pipe and
wherein said tubular housing surrounds said flue pipe.
16. A chimney cap device for a flue opening, which device
comprises: a tubular housing fabricated from sheet metal with an
open lower end and an open upper end; a plurality of louver
openings in a lower portion of the tubular housing to draw air into
said tubular housing; a removable top attached to said open upper
end of said tubular housing wherein said top includes a plurality
of exit openings; a removable catalytic converter filter insert;
and a plurality of supports extending from said liner to hold said
filter insert within said tubular housing.
17. A chimney cap device for a flue opening as set forth in claim
16 including an inner frame and mounting assembly attached near
said open lower end of the tubular housing having anchoring and
leveling means to anchor said inner frame and mounting
assembly.
18. A process to treat carbon monoxide and unburned hydrocarbon
emissions generated from a gas fired appliance, which process
comprises: passing exhaust gases from said gas fired appliance from
a flue opening into a tubular housing of a chimney cap device;
permitting atmospheric air to pass through louver openings in a
lower portion of said tubular housing into the tubular housing;
permitting said exhaust gases and said atmospheric air in said
tubular housing to pass into and through a filter insert supported
within said tubular housing; treating emissions within said exhaust
gases with said filter insert; permitting gases passing through
said filter insert to be received in a removable top; and
permitting passage of gases from said removable top through a
plurality of exit openings in said removable top.
19. A process to treat emissions as set forth in claim 18 wherein
said step of treating emissions includes promoting oxidation with a
catalytic converter.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention is directed to a cap for a flue
opening of a building. In particular, the present invention is
directed to a cap for a flue opening having a replaceable filter in
order to reduce emissions generated by a gas fired device, to
extend the flue or chimney to enhance draw of exhaust, to protect
from the elements, and to protect from entry of animals and debris.
Additionally, the present invention provides a decorative external
feature for a building.
[0003] 2. Prior Art
[0004] Various types of flues and flue openings are known which are
used to carry exhaust upward out of a building into the atmosphere.
A wide range of chimney cap devices and chimney extensions have
been designed and utilized in the past. Various chimney caps in the
past have been constructed of clay or masonry. While functional and
decorative, they are extremely heavy and difficult to move to a
rooftop.
[0005] Lightweight, metal chimney caps have also been utilized.
Examples include Assignee's U.S. Pat. No. 6,926,600, Assignee's
U.S. Pat. No. 7,179,164, and Assignee's U.S. Design Pat. No.
D535,010.
[0006] Various different types of gas fired devices are utilized in
buildings which burn natural gas, propane, or other light
hydrocarbon gases. These include gas fired fireplaces, gas fired
hot water heaters, gas fired room heaters and other devices. In
most instances, these devices require exhaust through a flue pipe
and a flue opening through the roof of the building. While gas
fired devices are fairly efficient, they emit a certain amount of
carbon monoxide (CO) and unburned hydrocarbons.
[0007] Catalytic converters are known devices used to reduce the
toxicity of various emissions. For example, catalytic converters
have been used on automobiles for a number of decades. An example
of a catalytic converter is seen in U.S. Pat. No. 3,441,381 titled
"Apparatus For Purifying Exhaust Gases of An Internal Combustion
Engine". In one type of catalytic converter, carbon monoxide is
converted to carbon dioxide and unburned hydrocarbons are converted
to carbon dioxide and water.
[0008] Typically these devices must operate with temperatures above
600.degree. C. for the catalysts to activate and oxidize CO and
other unburned hydrocarbons. The present invention will operate at
much lower temperatures (i.e. less than 200.degree. C.).
[0009] There remains a need for a chimney cap device to reduce
carbon monoxide and unburned hydrocarbon emissions generated in gas
fired devices before they are exhausted into the environment.
[0010] There remains a need for a chimney cap device for a flue
opening for gas fired devices having a catalytic filter.
[0011] There remains a need for a chimney cap device for a flue
opening having a catalytic filter that is replaceable by accessing
an opening in the chimney cap device.
[0012] There remains a need for a chimney cap device with a
replaceable catalytic filter insert that is both lightweight and
decorative.
SUMMARY OF THE INVENTION
[0013] The present invention is directed to a chimney cap device
for a flue opening of a building. The device includes a tubular
housing having an open lower end which fits over a flue pipe of the
flue opening. The tubular housing also includes an open upper end
opposed to the lower end.
[0014] A plurality of louver openings are provided in a lower
portion of the tubular housing near the open lower end. The louver
openings permit atmospheric air to enter the tubular housing and
mix with exhaust gases from the flue pipe.
[0015] A removable top is attached to the open upper end of the
tubular housing. The removable top includes a plurality of exit
openings so that exhaust gases which pass through and out of the
flue pipe will proceed upward through the tubular housing, into the
removable top, and thereafter, out of the exit openings.
[0016] A metal liner is located within and spaced from the tubular
housing. An opening or openings are provided through the liner
adjacent the louver openings so that atmospheric air passing
through the louver openings will not only pass into a space between
the tubular housing and the liner, but will also pass info the
tubular housing and be drawn upward toward the removable top.
[0017] The chimney cap device also includes a removable filter
insert received in an optional carrier or holder having an open top
and an open bottom. The carrier and filter insert are supported
within the inner sleeve by a plurality of supports.
[0018] The filter insert promotes a chemical reaction wherein
carbon monoxide from the exhaust gas is converted into carbon
dioxide and wherein unburned hydrocarbons are converted into carbon
dioxide and water. These gases and vapors are earned out the
exhaust openings to the atmosphere.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a sectional view of a chimney cap device with a
replaceable or recyclable catalytic filter insert for a flue
opening constructed in accordance with the present invention;
[0020] FIG. 2 is an exploded view of the chimney cap device
illustrated in FIG. 1;
[0021] FIG. 3 is a front view of the chimney cap device shown in
FIG. 1 and FIG. 4 is a front view of the chimney cap device shown
in FIG. 3 with portions cut away for clarity;
[0022] FIG. 5 is a sectional partial view of the chimney cap device
shown in FIG. 1;
[0023] FIG. 6 is a sectional view of the chimney cap device taken
along section line 6-6 of FIG. 5; and
[0024] FIG. 7 is a sectional view of the chimney cap device taken
along section line 7-7 of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The embodiments discussed herein are merely illustrative of
specific manners in which to make and use the invention and are not
to be interpreted as limiting the scope of the instant
invention.
[0026] While the invention has been described with a certain degree
of particularity, it is to be noted that many modifications may be
made in the details of the invention's construction and the
arrangement of its components without departing from the spirit and
scope of this disclosure. It is understood that the invention is
not limited to the embodiments set forth herein for purposes of
exemplification.
[0027] Referring to the drawings in detail, FIG. 1 is a sectional
view of a chimney cap device 10 for a flue opening of the present
invention while FIG. 2 is an exploded view of the device 10 shown
in FIG. 1.
[0028] The chimney cap device 10 includes a tubular housing 12
which may take a number of configurations. The tubular housing has
an open lower end 14 which fits over a flue pipe 20 of a flue
opening of a building (not shown). The flue pipe 20 receives
exhaust from a gas fired device in a building. It will be
appreciated that the present invention may be utilized with a wide
variety of flue openings and flue pipe configurations.
[0029] The tubular housing 12 also includes an open upper end 16
opposed to the lower end 14. The tubular housing 12 may be
fabricated from flat sheet metal or other lightweight material. The
tubular housing 12 may be configured so that a cross-section of the
housing is in the form of a square, an octagon, a hexagon, a
rectangle, a circle, or other configuration.
[0030] A plurality of louver openings 18 are provided in a lower
portion of the tubular housing 12 near the open lower end 14. In
one embodiment, the louver openings 18 are stamped or otherwise
formed into the tubular housing 12. The louver openings 18 permit
atmospheric air to enter the tubular housing and mix with exhaust
gases from the flue pipe.
[0031] It will be appreciated that the present invention extends
the length of the flue to enhance draw of the exhaust.
[0032] A removable top 24 is attached to the open upper end 16 of
the tubular housing 12. The removable top 24 is shown apart from
the device in the exploded view in FIG. 2. The removable top 24
includes a plurality of exit openings 26. The exit openings 26 may
be stamped, punched, formed, or otherwise made into the sidewalls.
The total area of the exit openings is greater than the
cross-sectional area of the flue pipe. Accordingly, exhaust gases
which pass through and out of the flue pipe 20 will proceed upward
through the tubular housing 12 into the removable top 24 and
thereafter out of the exit openings 26. In addition, atmospheric
air may be drawn into and through the louver openings 18 of the
tubular housing, through the tubular housing 12, into the removable
top 24, and out of the exit opening 26.
[0033] The cap device 10 also includes an inner frame and mounting
assembly 22 attached near the open lower end 16 of the tubular
housing 12. The inner frame and mounting assembly 22 includes an
anchoring and leveling mechanism to anchor the inner frame and
mounting assembly to the building (not shown). In particular, the
anchoring and leveling mechanism may be used to anchor the inner
frame and mounting assembly to a chimney or to a roof 40.
[0034] One embodiment of an inner frame and mounting assembly is
disclosed in detail in Assignee's U.S. Pat. Nos. 7,179,164 and
6,926,600, which are incorporated herein by reference.
[0035] The removable top 24 includes a pyramidal upper section 30.
An optional heat deflector 32 beneath the pyramidal upper section
30 assists in creating turbulence in the exhaust gases and air. The
turbulence assists in directing the exhaust gases and air out of
the exit openings 26. An optional rain guard 34 may be installed
inside of the removable top 24 to discourage rain from passing
through the exit openings 26 into the tubular housing.
[0036] A metal liner 50 is located within and spaced from the
tubular housing 12. An opening or openings are provided through the
liner 50 adjacent the louver openings 18 so that atmospheric air
passing through the louver openings 18 will not only pass into the
space between the tubular housing 12 and the liner 50, but will
also pass into the tubular housing 12 and be drawn upward toward
the removable top. The air drawn into the space between the tubular
housing 12 and the liner 50 acts to insulate the tubular housing 12
from the heat of the exhaust.
[0037] The chimney cap device 10 also includes a removable filter
insert 60. The filter insert 60 is received into an optional
carrier or holder 62 having an open top and bottom. FIG. 3
illustrates a front view of the chimney cap 10 and FIG. 4
illustrates a front view partially cut away for clarity. As seen in
the partial sectional view in FIG. 5 and a sectional view in FIG.
7, a carrier 62 has an outwardly extending upper edge 52 which
mates with the tubular housing and the liner 50 of the tubular
housing. The carrier 62 and the filter insert 60 are supported
within the inner sleeve 50 by a plurality of supports 64 which may
take the form of metal L brackets. Other types of supports may be
utilized within the scope of the present invention.
[0038] Once the top 24 has been removed from the device 10, the
carrier 62 and its accompanying filter 60 may be removed.
[0039] Arrows 70 in FIG. 5 illustrate the path of exhaust gases
from the flue opening which pass into and through the filter insert
60.
[0040] The filter insert 60 promotes a chemical reaction wherein
carbon monoxide from the exhaust gas is converted into carbon
dioxide and wherein unburned hydrocarbons are converted to carbon
dioxide and water which are carried out the exit openings. Carbon
monoxide combines with oxygen to form carbon dioxide and unburned
hydrocarbons combine with oxygen to form carbon dioxide and
water.
[0041] Various types of filter inserts may be employed. One type of
catalytic converter includes a core or substrate fabricated from a
ceramic honeycomb. The ceramic honeycomb has a series of thin
walled rectangular channels which permit passage of gases
therethrough. The openings are greater than the cross-section of
the area of the flue pipe.
[0042] A washcoat is applied to the substrate core which may be a
mixture of silicon and aluminum. The washcoat forms a rough,
irregular surface. An oxidation catalyst is added to the washcoat
in suspension before application to the core. The catalyst may be
chosen from a variety of metal ingredients such as platinum,
rhodium and/or palladium. Other types of metals might also be
employed. The catalyst may be designed to operate at maximum
efficiency between 140.degree. F. (60.degree. C.) and 300.degree.
F. (149.degree. C.).
[0043] When in operation, the exhaust gases from the gas fired
appliance, such as a gas fired fireplace, pass from the fireplace
into and through the flue pipe 20. The exhaust gases mix with
incoming atmospheric air entering through the louver openings 18 of
the tubular housing. The gas mixture contacts the catalyst on the
filter insert 60 whereby the carbon monoxide and the unburned
hydrocarbons are oxidized to carbon dioxide (CO.sub.2) and water
(H.sub.2O). The purified gases are thereafter discharged into the
removable top 24 and out of the exhaust openings.
[0044] Periodically, the removable top 24 may be separated from the
device 10 by removing fasteners 58 shown exploded in FIG. 2. The
filter insert 60 may be removed and cleaned, replaced or
recycled.
[0045] It is estimated that more than 20 percent (20%) of the
carbon monoxide and unburned hydrocarbons may be destroyed through
use of the present invention.
[0046] The preferred embodiment described herein applies to a
passive catalytic converter, however, an electrical heating element
may be added to the filter insert to raise the operating
temperature.
[0047] The present invention might also be modified to include a
sensor in or adjacent the filter insert to sense if the filter
becomes plugged. In that event, a visual and/or audible alarm wired
to the sensor would be triggered.
[0048] Whereas, the present invention has been described in
relation to the drawings attached, hereto, it should be understood
that other and further modifications, apart from those shown or
suggested herein, may be made within the spirit and scope of this
invention.
* * * * *